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This document is intended to be an extended version of the testing plan from the PVDR (preliminary vehicle design report).

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Production Module Validation:

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To validate the "completed" battery modules, it is essential to conduct a full charge-discharge test while monitoring key system parameters such as voltage and temperature. While the continuous discharge of modules at 40+A is unlikely, this validation procedure functions as a stress test.

Initiate the procedure by charging the module to 16.6V (below the maximum to provide a health-span buffer).

Charging

Owen Li to complete the procedure.

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The modules will be charged to

Discharge Testing

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Equipment

  • BK Precision 8600 E-load

  • Rigol DL3031 E-load

  • 6, 18AWG wires with banana connectors

  • A2D DAQ w/ thermistors

  • USB to USB B (Data-Transfer Cable)

  • Windows Laptop

Software Setup

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https://github.com/kostubhagarwal/module_test_data_acquisition

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Procedure

  1. Connect A2D DAQ to Windows laptop.

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  1. Run serial_to_csv.py to check the functionality of the thermistors (only working thermistors will show readings on the terminal).

  2. Pause (Ctrl-C) serial_to_csv.py, then complete the physical setup.

  3. Connect working 6 thermistors to the battery module busing

    1. use electrical or kapton tape. ensure good contact!

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    1. attach to 6 different

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    1. central locations on the module as shown

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  1. Connect E-Loads to battery module as shown DONT MESS UP THE POLARITY OF TERMINALS

    1. two wires (one for each terminal) to connect BK Precision 8600 E-load to the battery module

    2. use four wires (double-up for each terminal, as wires are not rated for 30A) to connect Rigol DL3031 E-load to the battery module

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  1. Set BK Precision 8600 E-Load to 10A CC draw

  2. Set Rigol DL3031 E-Load to 30A CC draw

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  1. Run serial_to_csv.py

  2. Start both e-loads

  3. Once modules reach 11V (to prevent draining module past safe spot) stop the e-loads

  4. Terminate (Ctrl-C >> 2) serial_to_csv.py

  5. Save the 'data.csv' file with a different name, as it will be overwritten during the next run of serial_to_csv.py.

  6. Follow charging procedure to charge battery pack to 13.2V, this leaves cells at 3.3V which is a good storage voltage.

Storage Charge

Why?

Modules will be charged at 22A to 17V (4.25V per cell). We charge to 4.25V because it yields 105-110% of the rated energy storage https://batteryuniversity.com/article/bu-808-how-to-prolong-lithium-based-batteries . Charging to this higher voltage is allowed because it is still within the spec of our LG M50s (4.2V +- 0.05V). The downside to charging to a high voltage is reduced cyclability, but this is irrelevant to our low cycle use-case.

Another concern is storage. Cell voltage and temperature have a great effect on recoverable capacity.

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https://batteryuniversity.com/article/bu-808-how-to-prolong-lithium-based-batteries

At 4.25V (105-110% charge), the recoverable capacity will be even lower.

Therefore, we will discharge test fully charged modules as soon as possible to avoid prolonged storage at high SOC. After a full discharge, modules will be recharged to a storage voltage of 14.8V (3.7V) per cell to minimize capacity loss and self-dischargehttps://batteryuniversity.com/article/bu-702-how-to-store-batteries.

How?

To discharge the modules, use the battery test mode on the RIGOL DL3031 E-Load.

  1. Follow the instructions in Chapter 2: Application Function: Battery Test Function in the RIGOL User Manual to enter the Battery Test Mode.

  2. Set discharge current to 8A (approx 0.2C per cell, the standard discharge in the cell datasheet to minimize stress on the module).

  3. Set V_Stop to 14.3V

    1. We want to discharge to 3.7V per cell, which would be a module voltage of 14.7V. But keep in mind, voltage of a battery sags due to internal resistance. So why 14.3? Through experimentation, the internal resistance of a module is approximately 50mOhms. We are discharging at 8A. The voltage drop from the load would be V(drop) = IR = 8(0.05) = 0.4V.

  4. Start Discharge

Pack and Electrical System Validation:

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